Column heater with improved heat output

ABSTRACT

A radiant area heater includes a columnar base with a hollow compartment and a heating column disposed on the columnar base. The heating column includes a control portion with at least one controller, a burner, and a sparker and a flame portion that includes a combustion chamber. The combustion chamber is disposed on a cylindrical member that has at least one vent allowing air to circulate to the burner and within the combustion chamber. The heating column further includes at least one heat emitting screen disposed above the flame portion that radiates heat outwards from the heater. A cover is disposed over the heating column to direct heat outwards and away from the heater.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of and priority to U.S. ProvisionalApplication No. 62/168,646 which was filed May 29, 2015, the contents ofwhich are hereby incorporated by reference.

BACKGROUND 1. Field

The disclosed embodiments relate to heating apparatuses. Morespecifically, the disclosed embodiments relate to area heaters, such asoutdoor patio heaters.

2. Related Art

Many people enjoy sitting, eating, and socializing in outdoor settings.In such settings, people may enjoy fresh air, natural light, and/or theambience of the community or other surroundings. Accordingly, manyrestaurants include outdoor seating as an option for their customers.Homeowners may also utilize outdoor furniture on a patio, porch, or deckto enjoy time outside alone or with others.

However, many climates have at least a portion of the year wheretemperatures are generally too cold to allow people to comfortably sitoutside. Additionally, even during warmer months, evenings or nights maybecome sufficiently cool that people no longer wish to remain outdoors.For a restaurant, this may result in being unable to utilize an outdooreating area. For a homeowner, this may limit the homeowner's use andenjoyment of his or her patio or deck.

Because of this, patio heaters have been developed to provide heat tooutdoor areas to allow people to comfortably remain outdoors even whenthe outside temperature cools. Typical patio heaters provide radiantheat to an area surrounding the heater. Such patio heaters may use anelectrical heating element or a natural gas burner with a radiant heatemitter screen.

While such patio heaters provide radiant heat, they are not alwaysaesthetically pleasing. In fact, many people would prefer a heater thatincorporates a natural looking flame. The ambience created by a naturallooking flame is thought to increase the overall ambience of thesurroundings. Furthermore, during evening or night hours, the flameprovides a warm, ambient light.

As a result, patio heaters have been developed to incorporate a naturallooking flame. However, such patio heaters have been found to have anumber of drawbacks. Such patio heaters, while utilizing a flame, do notproduce as much heat output as traditional radiant heaters. As a result,a user of such a patio heater would need to invest in more natural flamepatio heaters and would spend more money in the resulting fuel requiredto operate the heaters.

SUMMARY

In light of the above, the disclosed embodiments have been developed toprovide an area heater such as patio heater utilizing a natural flamevisible to users while maintaining a high heat output. In one suchembodiment, a radiant area heater includes a columnar base with a hollowcompartment and a heating column disposed on the columnar base. Theheating column includes a control portion with at least one controller,a burner, and a sparker, and a flame portion that includes a combustionchamber. The combustion chamber is disposed on a cylindrical member thathas at least one vent allowing air to circulate to the burner and withinthe combustion chamber. The heating column further includes at least oneheat emitting screen disposed above the flame portion that radiates heatoutwards from the heater. A cover is disposed over the heating column todirect heat outwards and away from the heater.

In some embodiments, the radiant area heater may include a base flangedisposed at a bottom of the columnar base. The base flange may includeat least one wheel allowing the heater to be easily moved. The columnarbase may also include a removable panel allowing access to the hollowcompartment. The removable panel may be a door attached to the columnarbase via hinges. The door may be releasably secured in a closed positionby a latch. The removable panel may include at least one air ventilationhole.

In other embodiments, the at least one heat emitting screen may includean upper heat emitting screen and a lower heat emitting screen. Theupper heat emitting screen may be configured with a width that isgreater than a width of the lower heat emitting screen. In someinstances, the width of the lower heat emitting screen is substantiallyequal to a width of the combustion chamber. The width of the combustionchamber may be configured to be at least 200 mm.

The radiant area heater may further include a wire cage disposed aroundthe flame portion and the at least on heat emitting screen. The columnarbase and heating column may be configured to be cylindrical in shape.

In some embodiments, there a radiant area heater may include acylindrical columnar base. The columnar base may include a base flangeat a bottom of the columnar base, the base flange having at least onewheel to allow a user to move the area heater. The columnar base mayfurther include a hollow compartment configured to house a fuel tanktherein. A middle flange may be disposed above the columnar base.

The area heater may further include a cylindrical control portion thathas at least one controller, a burner, and a sparker. A cylindricalflame portion may be disposed above the middle flange. The flame portionmay include a transparent cylindrical combustion chamber disposed abovesaid burner. The combustion chamber may be held and supported by acylindrical supporting member. The cylindrical supporting member mayinclude at least one vent allowing air to circulate to the burner andwithin the combustion chamber.

At least one heat emitting screen may be disposed above of thecombustion chamber. A wire cage may be provided to surround thecombustion chamber and the at least one heat emitting screen. A covermay be disposed above the at least one heat emitting screen in order todirect heat outward from the heater.

In some embodiments, the at least one heat emitting screen comprises anupper heat emitting screen and a lower heat emitting screen. The upperheat emitting screen may have a diameter that is greater than a diameterof the lower heat emitting screen. The diameter of the lower heatemitting screen may be substantially equal to a diameter of thecombustion chamber. The diameter of the combustion chamber may be atleast 200 mm.

In other embodiments, the middle flange may include a handle tofacilitate the transportation of the area heater. The control portionmay also include a pilot light to light the burner. In some instances,at least a portion of the wire cage may be removable.

Also disclosed is a column heater comprising a base configured tosupport the heater with a burner located in or above the base. Theburner is in gaseous communication with a source of combustible gas. Acombustion area extends upward from the base and is located above theburner. The combustion area has a cross sectional area of greater than706 square centimeters. Also part of this embodiment are air ventsadjacent or below the combustion area such that the air vents have anarea greater than an area of the burner to allow air flow into thecombustion area to complete combustion of the combustible gas. A topcover above the combustion area is configured to radiate heat downwardand outward.

This embodiment may further comprise one or more radiant heating screenlocated above the combustion area such that the one or more radiantheating screens are configured to receive heat rising from thecombustion chamber and radiate the heat outward from the heater.

The one or more radiant heating screens may comprise an upper screen anda lower screen such that the upper screen having a diameter that isgreater than the lower screen. The combustion area maybe enclosed in atransparent or semi-transparent enclosure. It is contemplated that thecombustion area may be configured to present flame from the burner, theflame having a height of greater than 60 centimeters. In one embodimentthe base is round to increase stability and the combustion chamber isround to thereby provide equivalent heat output at all radial locationsalong a fixed radius outward from the heater.

Other systems, methods, features and advantages of the invention will beor will become apparent to one with skill in the art upon examination ofthe following figures and detailed description. It is intended that allsuch additional systems, methods, features and advantages be includedwithin this description, be within the scope of the invention, and beprotected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of an area heater according to one exemplaryembodiment.

FIG. 2 is a side view of the area heater shown in FIG. 1.

FIG. 3 is a front view of the area heater shown in FIG. 1 which shows adoor to a compartment in the open position.

FIG. 4 is an enlarged perspective view of a burner of the area heatershown in FIG. 1.

FIG. 5 is an enlarged perspective view of a heat emitting screen portionof the area heater shown in FIG. 1.

FIG. 6 is a view of the area heater shown in FIG. 1 in operation,according to an exemplary embodiment.

The components in the figures are not necessarily to scale, emphasisinstead being placed upon illustrating the principles of the invention.In the figures, like reference numerals designate corresponding partsthroughout the different views.

DETAILED DESCRIPTION OF EMBODIMENTS

FIG. 1 is a front view of an area heater according to one exemplaryembodiment, and FIG. 2 is a side view of the area heater shown inFIG. 1. In this embodiment, a radiant induction area heater 100 includesa columnar base 110 on which a heating column 160 sits. The columnarbase 110 may be formed of a flame resistant material such as a metal,ceramic, composite, and the like. The columnar base 110 may beconfigured with a decorative exterior, such as to resemble bricks,stone, or any other decorative motif.

In one embodiment, the columnar base 110 includes a base flange 112. Thebase flange 112 has a diameter that extends beyond the diameter of thecolumnar base 110 and provides stability to the overall structure of theheater 100 as it sits on a surface. An axle 132 and pair of wheels 130may be mounted to the base flange 112 to allow for easy transportationof the heater 100. The wheels 130 may be configured to be raisedslightly from the ground when the heater 100 rests flat on a surface. Inthis way, the wheels 130 only allow movement of the heater 100 when theheater 100 is tilted back at an angle allowing the wheels 130 to come incontact with the ground.

The columnar base 110 further defines a hollow compartment 115 (see FIG.3) within its cylindrical wall. To access the compartment 115, thecolumnar base 110 has a removable panel or door 114. The panel or door114 may be removable via any suitable manner. For example, the door 114may rotate via hinges 116 between open and closed positions. In order tohold the door 114 closed during use, the door 114 may be latched via alatch 118.

The door 114 may include ventilation holes 120 to allow air to circulatewithin the compartment 115. The door 114 may also include an access hole122 that facilitates the opening and closing of the door 114. In otherembodiments, a handle may be used in place of the access hole 122.However, the access hole 122 provides additional ventilation to thecompartment 115.

Above the columnar base 110, as shown in FIGS. 1 and 2, a middle flange140 is provided. The middle flange 140 provides additional structuralsupport to the heater 100 while also aesthetically matching with thebase flange 112. The middle flange 140 may optionally include a handle134. The handle 134 allows a user to easily hold the heater 100 and tiltit back on its wheels 130, thereby easily moving the heater to anotherlocation.

The heating column 160 is disposed above the middle flange 140. Theheating column 160 includes a control portion 166, a flame portion 165,and a screen portion 180. The control portion 166 comprises a number ofcontrols 168. In this embodiment, the controls 168 may include a startercontroller and a fuel valve controller. The starter controller maycontrol a sparker (described below). The controls 168 allow a user toturn the heater 100 on and off and to control the amount of heat emittedfrom the heater 100.

The flame portion 165 includes one or more vertical support members 161supporting a wire cage 162. The wire cage 162 is provided to preventpersons around the heater 100 from getting too close to the heat sourceof the heater 100. The support member 161 and wire cage 162 may beformed from any suitable flame resistant material such as metals orcomposites. The wire cage 162 may be configured to be at least partiallyremovable. For example, the wire cage 162 may be sectioned between thesupport members 161. One or more sections of the wire cage 162 betweenthe support members 161 may be configured to be removed to allow accessinto the wire cage 162 for cleaning and maintenance.

The wire cage 162 and support members 161 surround a transparentcombustion chamber 164. In this embodiment, the combustion chamber 164is formed in a cylindrical or tubular shape. The transparent combustionchamber is constructed from a flame and heat resistant material. Forexample, the transparent combustion chamber 164 may be formed from atempered glass, borosilicate glass, a high temperature, transparentpolymer, or the like.

The combustion chamber 164 is supported by a cylindrical member 170disposed on top of the control portion 166. The screen portion 180 isconfigured to be disposed above the heating chamber 164. The screenportion 180 is described in more detail below. The heater 100 alsoincludes a top cover 167. The top cover 167 may be metallic and isconfigured to radiate heat outwards and away from the heater 100 to heatthe surrounding area.

FIG. 3 is a front view of the area heater shown in FIG. 1 in which adoor to a compartment is in the open position. In this embodiment, whenthe door 114 is in the open position, a fuel tank 126 may be accessedwithin the compartment 115. For example, an empty fuel tank 126 may beremoved and replaced with a full fuel tank 126 when the door 114 is inthe open position. The compartment 115 includes a fuel tank base 124which supports the fuel tank 126 and holds the fuel tank 126 inposition. A fuel line 128 may extend from the control portion 166 of theheater 100 into the compartment 115 to attach to the fuel tank 126.

FIG. 4 is an enlarged perspective view of a burner of the area heatershown in FIG. 1. As shown in FIG. 4, a portion of the wire cage 162between two supports 161 is may be removed to allow access within thewire cage 162, as described above. In FIG. 4, a portion of the wire cage162 is shown as removed for ease in explanation. In this embodiment, thecylindrical member 170 includes a plurality of brackets 176. Thecombustion chamber 164 is configured to rest on the brackets 176 of thecylindrical member 170. The cylindrical member 170 further comprisesmounting brackets 174 which securely affix the cylindrical member 170 tothe control portion 166.

A plurality of ventilation holes 172 are formed in the cylindrical body170. In this embodiment, the ventilation holes 172 extend in an arrayaround the entire circumference of the cylindrical body 170. Theventilation holes 172 provide air circulation to enhance the combustionin the combustion chamber 164.

As seen in FIG. 4, the control portion 166 includes a burner 150. Theburner 150 may be ignited by a pilot light 152. Both the burner 150 andpilot light 152 may burn fuel provided from the fuel tank 126 via thefuel line 128 (see FIG. 3). To conserve fuel, the pilot light 152 may beconfigured to remain unlit during a period of storage. The controlportion 166 may thus also include a sparker 154 that provides a spark inresponse to the controls 168 to light the pilot light 152.

The flame emitted from the burner 150 is enhanced by the ventilationbuilt into the heater 100. This ventilation comes from the ventilationholes 120 and access hole 122 in the door 114, as well as the array ofvents 172 in the cylindrical member 170. The combustion chamber 164 isfurther configured to be sufficiently wide to allow for enhancedcombustion as compared to typical flame heaters. In one embodiment, adiameter 178 of the combustion chamber 164 is at least 150 mm. In someembodiments, the diameter 178 is at least 200 mm. In furtherembodiments, the diameter 178 is at least 250 mm. The width of thecombustion chamber 164 also allows the flames within the combustionchamber to be wider than typical flame heaters. This allows the flame tohave a natural look, increasing the aesthetics of the heater 100.

FIG. 5 is an enlarged perspective view of a heat emitting screen portionof the heater shown in FIG. 1. In this embodiment, the screen portion180 comprises a lower heat emitting screen 182 and an upper heatemitting screen 184. The lower heat emitting screen 182 is disposedabove the combustion chamber 164. The lower heat emitting screen 182 hasa diameter substantially equal to the combustion chamber 164. Flamesfrom the burner 150 heat the lower heat emitting screen 182 such thatthe screen 182 emits and radiates heat outward, as directed by the cover167.

The upper heat emitting screen 184 is disposed above the lower heatemitting screen 182. The upper heat emitting screen 184 is configured tohave a diameter that is greater than the lower heat emitting screen 182and the combustion chamber 164. The upper heat emitting screen 184 actsas a secondary heat emitting screen to absorb heat from the flames ofthe burner 150 that are not absorbed by the lower heat emitting screen182. Similar to the lower heat emitting screen 182, the upper heatemitting screen 184 radiates heat outward as directed by the cover 167.

FIG. 6 is a view of the area heater shown in FIG. 1 in operation,according to an exemplary embodiment. In order to operate the heater100, a user operates the controls 168 to light the pilot light 152 withthe sparker 154, which in turn lights the burner 150. The user cancontrol the amount of fuel flowing to the burner 150 via the controls168, thereby controlling the amount of heat emitted by the heater 100.

The burner 150 emits a flame up through the combustion chamber 164. Thecombustion is enhanced by the cylindrical member 170 supporting thecombustion chamber 164 and providing air circulation via the vents 172.The flames extend through the combustion chamber 164 providing adesirable ambience due to the visible flames. Heat radiates outward fromthe flames through the transparent combustion chamber 164 and wire cage162 to heat the surroundings. In addition, heat and hot gases risingfrom the flames through the combustion chamber 164 heat the lower andupper heat emitting screens 182, 184 which radiate additional heattowards the surrounding area.

In on embodiment the wire screen that surrounds the combustion chamberis make with numerous open sections in relation the wire that forms thescreen. By increasing the size of the openings in the wire screen thatsurrounds the combustion area or chamber, more heat can radiate outwardfrom the heater, thereby increasing the efficiency of each output for agiven amount of fuel. In one embodiment the opening are at least ½ inchby 1 inch. In another embodiment the openings are at least ½ inch by 1½inch. In one embodiment, the openings are at least ¾ inch by 1 inch. Inother embodiment the size of the openings may vary, but be greater thanthe prior art heaters.

As a further advantage to the present design over the prior art heaters,the amount of air provided to the combustion chamber and the combustionchamber itself is increased. Based on extensive research by theinventors it was discovered that prior art heaters lacked sufficientairflow to complete combustion. As disclosed herein, the area of the airvents around the burner (below, on the side, or both) is increased ascompared to the prior art. In one embodiment, the area for air to enterthe combustion chamber is greater than the area of the burner. In oneembodiment, the area for air to enter the combustion chamber is greaterthan 1.5 times the area of the burner.

Other modifications of the above described embodiments may also beimplemented. For example, while the general shape of the heaterdescribed above is cylindrical, the heater may be configured to besquare, rectangular, elliptical, or to be another shape. Further, inplace of a fuel storage tank, the heater may have a port to hook up toan external fuel supply.

The above described embodiments provide a number of advantages. Becausethe heater incorporates visible flames, the overall look and feel of theheater is enhanced. That is, people enjoy the light and the look that iscreated by flames. Further, because of the enhanced ventilation anddesign of the heater, the performance of the heater is better thantraditional flame heaters, as demonstrated in the following example.

EXAMPLE 1

A heater according to the above embodiments was tested for performanceagainst a traditional gas powered radiant heater and a known flameradiant heater. For each heater tested, temperature was measured atdistinct distances away from the heater to determine the heat emittedfrom each heater. Each heater in the test was configured to consume46,000 BTU. The results of the test are shown in Table 1.

Measurement point (inches) 19.7 25.6 31.5 37.4 43.3 49.2 55.1 61.0 66.9Traditional Radiant 131.4 124.9 124.2 113.9 112.8 109.8 105.4 100.8100.6 Heater (° F.) Traditional Flame 116.8 113.0 109.6 107.1 104.9103.6 102.7 101.8 100.4 Heater (° F.) Rapid Induction Area 142.7 129.9120.6 116.2 113.9 110.7 102.0 102.0 101.7 Heater (° F.)

As shown from the above results, the rapid induction area heater has aperformance that is similar to traditional radiant heaters while alsoincorporating a design with a visible flame. In comparison withtraditional flame heaters, the performance of the rapid induction areaheater as described in the above embodiments is significantly higherthan the traditional flame heaters at a radial distance of closer thansix feet. Thus, the heater in the disclosed embodiments can provideperformance similar to a non-flame radiant heater while providing theambience desired from a traditional flame heater.

While various embodiments of the invention have been described, it willbe apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible that are within the scopeof this invention. In addition, the various features, elements, andembodiments described herein may be claimed or combined in anycombination or arrangement.

What is claimed is:
 1. A radiant area heater comprising: a columnar basethat includes a hollow compartment; a heating column disposed on thecolumnar base, the heating column comprising: a control portion thatcomprises at least one controller, a burner, and a sparker; a flameportion that comprises a combustion chamber, the combustion chamberbeing disposed on a cylindrical member, the cylindrical membercomprising at least one vent allowing air to circulate to the burner andwithin the combustion chamber; and at least one heat emitting screendisposed above the flame portion, the heat emitting screen radiatingheat outwards from the heater; and a cover disposed over the heatingcolumn, the cover being configured to direct heat outwards and away fromthe heater.
 2. The radiant area heater according to claim 1, furthercomprising a base flange disposed at a bottom of the columnar base, thebase flange comprising at least one wheel.
 3. The radiant area heateraccording to claim 1, wherein the columnar base comprises a removablepanel allowing access to the hollow compartment.
 4. The radiant areaheater according to claim 3, wherein the removable panel is a doorattached to the columnar base via hinges, the door being releasablysecured in a closed position by a latch.
 5. The radiant area heateraccording to claim 3, wherein the removable panel comprises at least oneair ventilation hole.
 6. The radiant area heater according to claim 1,wherein the at least one heat emitting screen comprises an upper heatemitting screen and a lower heat emitting screen, the upper heatemitting screen having a width that is greater than a width of the lowerheat emitting screen.
 7. The radiant area heater according to claim 6,wherein the width of the lower heat emitting screen is substantiallyequal to a width of the combustion chamber.
 8. The radiant area heateraccording to claim 1, wherein a width of the combustion chamber is atleast 200 mm.
 9. The radiant area heater according to claim 1, furthercomprising a wire cage disposed around the flame portion and the atleast on heat emitting screen.
 10. The radiant area heater according toclaim 1, wherein the columnar base and heating column are cylindrical inshape.
 11. A radiant area heater comprising: a cylindrical columnarbase, the columnar base comprising: a base flange at a bottom of thecolumnar base, the base flange comprising at least one wheel; and ahollow compartment configured to house a fuel tank therein; a middleflange disposed above the columnar base; a cylindrical control portion,the control portion comprising at least one controller, a burner, and asparker; a cylindrical flame portion disposed above the middle flange,the flame portion comprising: a transparent cylindrical combustionchamber disposed above said burner; a cylindrical supporting memberconfigured to hold the combustion chamber, the supporting membercomprising at least one vent allowing air to circulate to the burner andwithin the combustion chamber; at least one heat emitting screendisposed above of the combustion chamber; a wire cage disposed tosurround the combustion chamber and the at least one heat emittingscreen; and a cover disposed above the at least one heat emittingscreen, the cover configured to direct heat outward from the heater. 12.The radiant area heater according to claim 11, wherein the at least oneheat emitting screen comprises an upper heat emitting screen and a lowerheat emitting screen, the upper heat emitting screen having a diameterthat is greater than a diameter of the lower heat emitting screen. 13.The radiant area heater according to claim 12, wherein the diameter ofthe lower heat emitting screen is substantially equal to a diameter ofthe combustion chamber.
 14. The radiant area heater according to claim11, wherein a diameter of the combustion chamber is at least 200 mm. 15.The radiant area heater according to claim 11, wherein the middle flangecomprises a handle.
 16. The radiant area heater according to claim 11,wherein the control portion further comprises a pilot light.
 17. Theradiant area heater according to claim 11, wherein at least a portion ofthe wire cage is removable.
 18. A heater comprising: a base configuredto support the heater; a burner located in or above the base, the burnerin gaseous communication with a source of combustible gas; a combustionarea extending upward from the base and located above the burner, thecombustion area having cross sectional area of greater than 706 squarecentimeters; air vents adjacent or below the combustion area, the airvents having an area greater than an area of the burner to allow airflow into the combustion area to complete combustion of the combustiblegas; and a top cover above the combustion area configured radiate heatdownward and outward.
 19. The heater of claim 18, further comprising oneor more radiant heating screen located above the combustion area, theone or more radiant heating screens configured to receive heat risingfrom the combustion chamber and radiate the heat outward from theheater.
 20. The heater of claim 19, wherein the one or more radiantheating screens comprises an upper screen and a lower screen, the upperscreen having a diameter that is greater than the lower screen.
 21. Theheater of claim 18, wherein combustion area is enclosed in a transparentor semi-transparent enclosure.
 22. The heater of claim 18, wherein thecombustion area is configured to present flame from the burner, theflame having a height of greater than 60 centimeters.
 23. The heater ofclaim 18, wherein the base is round to increase stability and thecombustion chamber is round to thereby provide equivalent heat output atall radial locations along a fixed radius outward from the heater.